Backup Power Systems
In the event of a power loss, backup power systems provide a secondary source of power so that important processes and systems can remain operational. Backup power systems have long supported the critical power needs of hospitals, emergency responders, and utilities. As industrial and manufacturing processes have become more complex, the need for reliable backup power has increased.
Types of Industrial Backup Power Systems
If you are not familiar with backup power systems, they are categorized as “Emergency,” “Required Standby,” and “Not Required Standby.” The nature of the industrial, manufacturing, or utility process determines which type or types are necessary. Whatever the method, backup power systems reduce the risk of process or system failure and help prevent damage to people, property, and products.
Emergency Power Systems
Emergency Power Systems support highly critical processes and systems, providing power from an alternate source within 10 seconds. The two most common configurations for an Emergency Power System include:
Main-Tie-Main: This configuration consists of redundant power feeds, each connected to a power source. An automatic transfer switch (ATS) is installed between the power feeds. When the control system detects a loss of power on the primary power source, the ATS switches to a redundant power source. To prevent equipment damage and downtime, the ATS is installed to permit synchronized switching of power sources, and the redundant power feeds are phased alike.
Main-Tie-Main with Backup Generator Set: This configuration adds one or more generators as a secondary power source in case the redundant power feed also loses power.
Standby Power Systems
Standby Power Systems provide power from an alternate source within 60 seconds. During major power outages, Standby Power Systems power essential systems such as safety systems or lighting for access and egress. In addition to required systems, owners can choose to install additional generators, UPS battery systems, and inverters as needed or desired for additional safety and convenience.
Generators: Selected and sized for specific plant needs, generators often provide power to communication and alarm systems or essential lighting and controls. Generators may also be connected to equipment that requires power to complete a controlled shutdown sequence.
UPS Batteries: UPS Battery Systems keep plant control systems, including PLC and DCS equipment, operational during major power outages. These systems provide alternate power for a limited amount of time.
Inverters: Inverters convert DC power provided by generators or batteries to AC power.
For Backup Power System installation or replacement projects, we recommend customers begin planning and procurement at least six months in advance. Often, a facility's insurance company will establish design and maintenance requirements for power generation equipment as part of an insurance policy. Current codes and standards for backup power systems require fire-rated equipment and cables. Some installations require a conditioned space that offers protection from mechanical, water, and intentional damage. Also, certain equipment, such as fire protection equipment, requires different standards of installation due to its critical function.
Routine Maintenance of Backup Power Systems
Backup power systems, emergency or standby, are vital operations equipment. Regular, routine maintenance is necessary to make sure equipment will operate when needed and as intended. Maintenance should be completed by qualified personnel and can include:
Checking for loose connections and degraded cables or switches
Cleaning dirt and debris from connections
Checking fluid levels
Scanning for hotspots using infrared cameras
Testing critical cables using a high-potential testing machine or a less invasive Doble test for older cables.
SEFA Industrial Solutions provides electrical construction and installation of Backup Power Systems and connects and integrates instrumentation & control systems. Reach out if you would like to discuss an upcoming project involving a Backup Power System at your facility.